Automated identification and assembly of shoe parts

ABSTRACT

Manufacturing and assembly of a shoe or a portion of a shoe is enhanced by automated placement and assembly of shoe parts. For example, a part-recognition system analyzes an image of a shoe part to identify the part and determine a location of the part. Once the part is identified and located, the part can be manipulated by an automated manufacturing tool.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application Ser. No. 14/267,503, entitled “AUTOMATED IDENTIFICATIONAND ASSEMBLY OF SHOE PARTS” is a Continuation Application of co-pendingU.S. application Ser. No. 13/299,872, filed Nov. 18, 2011, and entitled“AUTOMATED IDENTIFICATION AND ASSEMBLY OF SHOE PARTS.” The entirety ofthe aforementioned application is incorporated by reference herein.

BACKGROUND

Manufacturing a shoe typically requires various assembly steps, such asforming, placing, and assembling several parts. Some methods ofcompleting these steps, such as those that rely heavily on manualexecution, can be resource intensive and can have a high rate ofvariability.

SUMMARY

This summary provides a high-level overview of the disclosure and ofvarious aspects of the invention and introduces a selection of conceptsthat are further described in the detailed-description section below.This summary is not intended to identify key features or essentialfeatures of the claimed subject matter, nor is it intended to be used asan aid in isolation to determine the scope of the claimed subjectmatter.

In brief and at a high level, this disclosure describes, among otherthings, the manufacturing and assembly of a shoe, such as an automatedplacement and attachment of shoe parts. For example, a part-recognitionsystem analyzes an image of a shoe part to identify the part anddetermine a location of the part. Once the part is identified andlocated, the part may be manipulated in an automated manner. Forexample, a first identified part may be placed at a desired location onsecond identified part using a manufacturing tool. Further, the firstidentified part may be attached to the second identified part using themanufacturing tool.

An exemplary system that positions and attaches a shoe part in anautomated manner may have various components, such as an image recorderthat records an image depicting a representation of an attachment shoepart. The system may also comprise a computing device that: (1)identifies a plurality of reference features of the two-dimensionalrepresentation of the attachment shoe part; (2) determines pixelcoordinates of the image that correspond to the plurality of referencefeatures; (3) converts the pixel coordinates of the image to a geometriccoordinate in a geometric coordinate system, which maps athree-dimensional space within which the attachment shoe part ispositioned and a manufacturing tool operates; and (4) determines anothergeometric coordinate in the geometric coordinate system by analyzing adifferent image of the base shoe part.

The system may further comprise the manufacturing tool which may have avacuum-powered part holder having a bottom surface adapted forcontacting the attachment shoe part and an ultrasonic-welding horncomprised of a distal end adapted for contacting the attachment shoepart such that the distal end extends at least to a plane defined by thevacuum-powered part holder bottom surface. The manufacturing tool may benotified of the other geometric coordinate and transfer the attachmentshoe part to the other geometric coordinate, thereby moving theattachment shoe part to a location in the three-dimensional space atwhich the attachment shoe part is to be temporarily attached to the baseshoe part.

An exemplary method for positioning and assembling a shoe part in anautomated manner during a shoe-manufacturing process may have varioussteps. For example, an image may be received that depicts atwo-dimensional representation of an attachment shoe part, which is tobe attached to a base shoe part. The two-dimensional representation ofthe attachment shoe part may be associated with at least one referencefeature that is identified. An identity of the image may be determinedby substantially matching the image to a reference image; the referenceimage has at least one pre-determined reference feature. In addition,pixel coordinates of the image may be determined that correspond to theat least one pre-determined reference feature and that may be convertedto a geometric coordinate of a geometric coordinate system.

Further, another geometric coordinate may also be determined byanalyzing a different image of the base shoe part to which theattachment shoe part will be attached. A multi-functional manufacturingtool may be utilized to transfer the attachment shoe part to the othergeometric coordinate. The multi-functional manufacturing tool may alsobe utilized to attach the attachment shoe part to the base shoe part

Another exemplary method of positioning and joining a plurality ofmanufacturing part utilizing automated identification of manufacturingparts and a manufacturing tool comprises of a vacuum-powered part holderand an ultrasonic-welding horn may also have various steps. Forinstance, a three-dimensional space within which a first manufacturingpart is positioned and the manufacturing tool operates may beautomatically identified. Further, a position of a second manufacturingpart may also be automatically identified. Based on the identificationof the first manufacturing part, the manufacturing tool may bepositioned such that the vacuum-powered part holder is proximate to thefirst manufacturing part. A vacuum force may then be generated andtransferred through a bottom surface of the vacuum-powered part holdersufficient to temporarily maintain the first manufacturing part incontact with at least a portion of the vacuum-powered part holder.

Continuing, based on the position of the second manufacturing part, thefirst manufacturing part may be transferred to the second manufacturingpart. The first manufacturing part may be subsequently released from thevacuum-powered part holder so that it is in contact with the secondmanufacturing part. The manufacturing tool may be positioned such thatthe ultrasonic-welding horn is proximate the first manufacturing part,and ultrasonic energy may be applied through the ultrasonic-weldinghorn, where the ultrasonic energy may be effective for joining the firstmanufacturing part with the second manufacturing part.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative examples of the present invention are described in detailbelow with reference to the attached drawing figures, wherein:

FIG. 1A depicts a schematic diagram of an exemplary system for shoe partidentification in accordance with the present invention;

FIG. 1B illustrates exemplary shoe-part references that may be generatedand analyzed in accordance with the present invention;

FIG. 2 depicts a schematic diagram of an exemplary system for shoe-partidentification in accordance with the present invention;

FIG. 3 depicts a flow diagram of a method for analyzing an image of ashoe part;

FIG. 4 depicts a schematic diagram of an exemplary image-recordingsystem;

FIGS. 5 and 6 depict a respective schematic diagram of an exemplarysystem for carrying out shoe-manufacturing methods;

FIGS. 7 and 8 depict a respective flow diagram of a method for analyzingan image of a shoe part;

FIG. 9 depicts a block diagram of an exemplary computing device that maybe used with systems and methods in accordance with the presentinvention;

FIG. 10 depicts a top-down view of an exemplary vacuum tool, inaccordance with embodiments of the present invention;

FIG. 11 depicts a front-to-back perspective cut view along a cut linethat is parallel to cutline 3-3 of the vacuum tool in FIG. 10, inaccordance with aspects of the present invention;

FIG. 12 depicts a front-to-back view of the vacuum tool along thecutline 3-3 of FIG. 10, in accordance with aspects of the presentinvention;

FIG. 13 depicts a focused view of the vacuum generator as cut along thecutline 3-3 from FIG. 10, in accordance with aspects of the presentinvention;

FIG. 14 depicts an exemplary plate comprised of the plurality ofapertures, in accordance with aspects of the present invention;

FIGS. 15-24 depict various aperture variations in a plate, in accordancewith aspects of the present invention;

FIG. 25 depicts an exploded view of a manufacturing tool comprised of avacuum tool and an ultrasonic welder, in accordance with aspects of thepresent invention;

FIG. 26 depicts a top-down perspective view of the manufacturing toolpreviously depicted in FIG. 25, in accordance with aspects of thepresent invention;

FIG. 27 depicts a side-perspective view of the manufacturing toolpreviously depicted in FIG. 25, in accordance with aspects of thepresent invention;

FIG. 28 depicts an exploded-perspective view of a manufacturing toolcomprised of six discrete vacuum distributors, in accordance withaspects of the present invention;

FIG. 29 depicts a top-down perspective of the manufacturing toolpreviously discussed with respect to FIG. 28, in accordance withexemplary aspects of the present invention;

FIG. 30 depicts a side perspective of the manufacturing tool of FIG. 28,in accordance with aspects of the present invention;

FIG. 31 depicts a manufacturing tool comprised of a vacuum generator andan ultrasonic welder, in accordance with aspects of the presentinvention;

FIG. 32 depicts a top-down perspective of the manufacturing tool of FIG.31, in accordance with aspects of the present invention;

FIG. 33 depicts a side perspective of the manufacturing tool of FIG. 31,in accordance with aspects of the present invention;

FIG. 34 depicts a cut side perspective view of a manufacturing toolcomprised of a single aperture vacuum tool and an ultrasonic welder, inaccordance with aspects of the present invention; and

FIG. 35 depicts a method for joining a plurality of manufacturing partsutilizing a manufacturing tool comprised of a vacuum tool and anultrasonic welder, in accordance with aspects of the present invention.

DETAILED DESCRIPTION

The subject matter of certain aspects of the present invention isdescribed with specificity herein to meet statutory requirements. Butthe description itself is not intended to define what is regarded as aninvention, which is what the claims do. The claimed subject matter maycomprise different elements or combinations of elements similar to theones described in this document, in conjunction with other present orfuture technologies. Terms should not be interpreted as implying anyparticular order among or between various elements herein disclosedunless explicitly stated.

In brief and at a high level, this disclosure describes, among otherthings, the manufacturing and assembly of a shoe, such as an automatedplacement and attachment of shoe parts. For example, a part-recognitionsystem analyzes an image of a shoe part to identify the part anddetermine a location of the part. Once the part is identified andlocated, the part may be manipulated in an automated manner. Forexample, a first identified part may be placed at a desired location onsecond identified part using a manufacturing tool. Further, the firstidentified part may be attached to the second identified part using themanufacturing tool.

A. Automated Identification of Shoe Parts

Subject matter described herein relates to an automated placement of ashoe part, and FIG. 1A depicts an exemplary system 10 that may performvarious actions in a shoe-manufacturing process. For example, a shoepart 12 may be provided at a supply station 14 together with severalother shoe parts. Supply station 14 may provide only a single type ofpart or multiple types of parts that are identified individually bysystem 10. Supply station 14 may comprise a conveyor belt, a table, arobotic arm, or any other device that can make shoe part 12 availablefor identification and/or manipulation in accordance with the presentinvention. An automated tool 16 may pick up the shoe part 12 from thesupply station 14, and the shoe part 12 may be transferred to anassembly station 18 by a multi-functional manufacturing tool 20. Themulti-functional manufacturing tool 20 may comprise a part-pickupportion, a part-transfer portion, and/or a part-attachment portion. Asused throughout this application, the terms part-pickup tool/apparatus,part-transfer tool/apparatus, part-attachment or attachmenttool/apparatus may comprise different names for the portions of themulti-functional manufacturing tool 20 and may be used interchangeablywith the term multi-functional manufacturing tool 20. Themulti-functional manufacturing tool 20 will be discussed in greaterdepth below.

A ghost depiction 21 of part-transfer apparatus is depicted toillustrate that the part-transfer apparatus may move to variouspositions. Moreover, various arrows 30 a-d are depicted that showpossible movement directions or rotations of respective components ofpart-transfer apparatus 20. Part-transfer apparatus 20 and the movementdirections and rotations depicted by FIG. 1A are exemplary only. Forexample, arrows 30 a and 30 d indicate that respective arms ofpart-transfer apparatus 20 may rotate, whereas arrows 30 b and 30 cindicate that respective arms may move vertically or horizontally (e.g.,in a telescoping manner). Although not depicted, arms of part-transferapparatus may also be comprised of articulating joints that enableadditional ranges of motion of part-transfer apparatus 20. The shoe part12 that is transferred may function as a base shoe part 24 at theassembly station 18. Alternatively, the shoe part 12 that is transferredmay be attached to a base shoe part 24 that is already positioned at theassembly station 18.

When identifying and/or placing shoe part 12 by part-transfer apparatus20, one or more cameras 22 a-f may record images of the shoe part 12that may be used to recognize the shoe part 12. The cameras 22 a-f maybe arranged at various positions in system 10, such as above a partsupply station (e.g., 22 a), on part-transfer apparatus 20 (e.g., 22 b),along a floor 26 (e.g., 22 c and 22 d), and/or above assembly station 18(e.g., 22 e and 22 f). In addition, the cameras 22 a-f may be arrangedat various perspectives, such as vertical (e.g., 22 b, 22 c, 22 d, and22 e), horizontal (e.g., 22 f), and angled (e.g., 22 a). The number,location, and/or orientation of cameras 22 a-f may vary beyond theexample illustrated in FIG. 1A.

The images may be used to determine a position and/or orientation of theshoe part 12 relative to part-transfer apparatus 20 and a position towhich shoe part 12 is to be transferred. Once the shoe part 12 has beenrecognized, other shoe-manufacturing processes may be carried out in amanual and/or an automated fashion, such as transferring the shoe part,attaching the shoe part via any attachment method, cutting the shoepart, molding the shoe part, etc.

In a further aspect, information (e.g., shoe-part identity andorientation) obtained by analyzing images of the shoe part 12 may becombined with information derived from other shoe-part analysis systemsin order to carry out shoe-manufacturing processes. For example, athree-dimensional (3-D) scanning system may derive information (e.g.,shoe-part surface-topography information, shoe-part-size information,etc.) from scans of the shoe part (or from scans of another shoe partthat is assembled with the shoe part), and the 3-D-system-derivedinformation may be combined with the shoe-part-identity and/or shoe-partorientation information. That is, the 3-D-system-derived information maybe determined upstream and communicated downstream to system 10 (or viceversa).

Information that is combined from different systems may be used invarious manners. In an exemplary aspect, if system 10 is used to attachshoe part 12 onto shoe part 24, information obtained from another systemmay be used to instruct and carry out an attachment method. For example,an amount of pressure may be calculated (based on information providedby another system) that is recommended to be exerted against the shoepart 12 in order to sufficiently attach the shoe part to one or moreother shoe parts 24. Such pressure measurements may be dependent onvarious factors determined and/or communicated from another system, suchas a size (e.g., thickness) of the shoe part and/or a number of shoeparts (e.g., layers) that are being attached.

Computing device 32 may help execute various operations, such as byanalyzing images and providing instructions to shoe-manufacturingequipment. Computing device 32 may be a single device or multipledevices, and may be physically integrated with the rest of system 10 ormay be physically distinct from other components of system 10. Computingdevice 32 may interact with one or more components of system 10 usingany media and/or protocol. Computing device 32 may be located proximateor distant from other components of system 10.

Light-emitting devices 28 may be positioned throughout system 10 and maybe used to enhance a contrast of shoe part 12 that may be useful when animage of shoe part 12 is used to recognize shoe part 12. Light-emittingdevices may be incandescent bulbs, fluorescent devices, LEDs, or anyother device capable or emitting light. A light-emitting device may bepositioned in various locations, such as near and/or integrated intosupply station 14 or part-pickup tool 16. Additionally, a light-emittingdevice may be positioned near or integrated into assembly station 18.Moreover, light-emitting devices may be positioned throughout the spacethat surrounds part-transfer apparatus 20, part-pickup tool 16, partsupply station 14, assembly station 18, and cameras 22 a-f. Varyingnumbers, types, and positions of light emitting devices may be used inaccordance with the present invention. Light emitting devices may beselected based upon the spectrum of light emitted and how that spectruminteracts with spectrums reflected by shoe part 12, supply station 14,assembly station 18, part-pickup tool 16, etc. For example,light-emitting devices may provide full-spectrum light and/orpartial-spectrum light (e.g., colored light).

Various aspects of FIG. 1A have been described that may also beapplicable to other systems described in this disclosure, such assystems depicted in FIGS. 2, 4, 5, and 6. Accordingly, when describingthese other systems, reference may also be made to FIG. 1A and aspectsdescribed in FIG. 1A may also apply in these other systems.

As indicated with respect to FIG. 1A, some aspects of the invention aredirected to using an image of a shoe part to identify certain shoe-partinformation, such as an identity of the shoe part and an orientation ofthe shoe part (e.g., position and rotation). The shoe-part identity andshoe-part orientation may then be used to carry out variousshoe-manufacturing steps (e.g., placement, attachment, molding, qualitycontrol, etc.). Accordingly, certain processes may be executed beforethe image is recorded in order to facilitate shoe-part-image analysis,and reference is made to FIG. 1B to describe such aspects.

FIG. 1B illustrates various depictions 1010 a-d, each of which providesone or more exemplary shoe-part reference patterns or models(hereinafter known as shoe-part references). For example, depiction 1010a provides an exemplary shoe-part reference 1012 a, and depiction 1010 bprovides a different shoe-part reference 1014 a. Depictions 1010 a-d mayrepresent data that is maintained in a computer-storage medium and isretrievable to execute computing functions. For example, depictions 1010a-d may be stored in a computer-storage media as reference models orpatterns and retrieved in order to be viewed on a computing outputdevice (e.g., computer display monitor).

Shoe-part references 1012 a and 1014 a may be determined and/or createdusing various techniques, such as by using a computer-assisted drawingprogram, an automatic shape-outlining computer program, or otherboundary-determination computer program. For example, an electronicimage of a shoe part may be recorded and analyzed by the automaticshape-outlining computer program, which automatically traces boundariesor perimeters of shapes that comprise the shoe part. In another aspect,shapes depicted in an electronic image of a shoe part may be manuallytraced using a computer-drawing application. In another example, a shoepart and/or a boundary associated therewith may be manually drawn usinga computer-drawing application. FIG. 1B depicts that shoe-partreferences may be comprised of a shoe-part perimeter or boundary (e.g.,1030), as well as an interior portion (e.g., 1032) bound by theperimeter 1030. As previously indicated, once created, a shoe-partreference may be electronically stored (e.g., item 234 in FIG. 2) andused in various manners, such as to analyze shoe-part images.

In one aspect, a shoe-part reference (e.g., shoe-part reference 1012 a)is created such that it may be scaled to correspond to a multiple ofdifferent shoe sizes. For example, a shoe-part reference correspondingto a model size (i.e., a model size for females and a model size formales) is created and all other matching shoe-part references are scaledoff of the shoe-part reference corresponding to the model size. Ashoe-part reference may be scaled up to, for example, five times toaccount for the different sizes. Further, the shoe-part reference can bescaled to allow for expansion and/or shrinkage for any particular size.

Continuing, references 1012 a and 1014 a may be used to determinereference information, which may be subsequently used to assemble shoeparts. For example, an attachment shoe part (e.g., 224 in FIG. 2) may bepositioned relative to a base shoe part (e.g., 226 in FIG. 2); however,before the attachment shoe part is positioned, it may be helpful todetermine a placement location at which the attachment shoe part shouldbe positioned.

As such, in an illustrative aspect, depiction 1010 c comprises areference 1014 b, which represents a physical boundary of a base shoepart, and a reference 1012 b, which represents a physical boundary of anattachment shoe part. In an exemplary aspect, reference 1012 b may bepositioned to overlay reference 1014 b and may be aligned with at leasta portion of the reference 1014 b. For example, boundary 1012 b may bemanually and/or automatically positioned (e.g., drag via input device)in a manner that is consistent with how an attachment shoe part would bearranged onto a base shoe part when the attachment shoe part will beattached to the shoe part. As such, depiction 1010 d illustrates adigitally rendered assembly of references 1016, which is comprised ofreference 1012 c aligned with reference 1014 c in a position consistentwith an attachment position.

In a further aspect of the invention, a reference feature 1020 may beidentified that aligns a portion of reference 1012 c with a portion ofreference 1014 c. As such, each of references 1012 c and 1014 ccomprises respective reference features that are generally aligned withone another. These respective reference features are shown in depiction1010 c and are identified by reference numerals 1021 and 1022. Forexample, a respective reference feature may be used to determine anorientation (e.g., position and rotation) of a shoe part, as well as aportion of the shoe part that aligns with another shoe part.

Now described is FIG. 2, in which an exemplary shoe-manufacturing system210 is depicted. System 210 may have a combination of shoe-manufacturingequipment and computing devices, which may assist in determiningautomated operations of the equipment. Operations carried out in system210 may facilitate manipulation of shoe part 224 and shoe part 226, suchas by transferring shoe part 224 and attaching shoe part 224 onto shoepart 226. For example, shoe parts 224 and 226 may comprise two differentpieces of flexible material, which are attached to one another to formpart of a shoe upper. Shoe parts 224 and 226 may comprise the same ordifferent types of flexible material, such as textiles, leathers, TPUmaterials, etc. Shoe parts 224 and 226 may be physical structures of thecompleted shoe and/or a component, such as an adhesive film, that may beused to join shoe components during the shoe manufacturing process.

A part-transfer apparatus 212, cameras 214 a and 214 b, and conveyor 222are examples of shoe-manufacturing equipment. A grid 225 is depicted inFIG. 2 (in broken lines) to convey that one or more items of theshoe-manufacturing equipment have a known position within a coordinatesystem (e.g., geometric coordinate system mapping a 3-D space withinwhich the equipment is positioned). Other items, such as shoe parts, maybe moved to known distances within the coordinate system. Although forillustrative purposes grid 225 only depicts two coordinates, axis arrows223 depict three axes.

Image analyzers 216 a and 216 b and dimension converter 218 representoperations and/or modules that may be carried out by a computing device.Moreover, FIG. 2 depicts that the shoe-manufacturing equipment maycommunicate with (i.e., be networked with) computing devices thatexecute the depicted operations by way of a network connection 227. Forexample, as will be described in more detail below, image analyzers 216a and 216 b may evaluate images recorded by cameras 214 a and 214 b torecognize shoe parts being utilized in the shoe manufacturing process.In addition, image analyzers 216 a-b and dimension converter 218communicate instructions to part-transfers apparatus 212. One example ofthis type of vision recognition system includes Cognex® machine visionsystems.

Components depicted in system 210 cooperate in different ways to assistin carrying out various steps of a shoe-manufacturing method. Forexample, some components of system 210 may operate collectively as partof a two-dimensional (“2-D”) part-recognition system, which is used todetermine various shoe-part characteristics, such as shoe-part identityand shoe-part orientation (e.g., placement and rotation) relative topart-transfer apparatus 212. For example, a part-recognition system maycomprise cameras 214 a-b, image analyzers 216 a-b, shoe-part datastore220, dimension converter 218, and some or all of part-transfer apparatus212.

A part-recognition system may be used in various manners within a shoemanufacturing process. For example, a part-recognition system may beused to execute a method 310 that is outlined in FIG. 3. Method 310relates to identifying a shoe part and determining an orientation (e.g.,geometric position and degree of rotation) of the shoe part. When anidentity and orientation of a shoe part is known or determined, the shoepart can be manipulated (e.g., transferred, attached, cut, molded, etc.)in an automated manner. In describing FIG. 3, reference will also bemade to FIG. 2 and FIG. 4.

At step 312, an image is recorded that depicts a representation of ashoe part. For example, an image may be recorded by camera 214 a or 214b and communicated to an image analyzer 216 a or 216 b. Exemplary images228 and 230 are illustrated in image analyzers 216 a and 216 b(respectively), and each image depicts a two-dimensional (“2-D”)representation 232 and 233 of a respective shoe part.

In step 314, an outline or perimeter of the representation as depictedin the image is recognized. For example, once image analyzer 216 aacquires image 228, image analyzer 216 a recognizes a perimeter oroutline of the 2-D representation 232 depicted in image 228. Perimeteror outline recognition may be enhanced using various techniques, such asby providing a background surface that highly contrasts a part depictedin the image, as well as by positioning various environment lightingelements (e.g., full-spectrum light-emitting devices). For example, if asurface of the shoe part that will be captured in the image is grey, abackground surface (e.g., surface of a supply station, a part-pickuptool, or an assembly station) may be colored yellow in order to create acontrast in the image between the outline of the part and thebackground. In one aspect, shoe-part inward-facing surfaces (i.e., aside of the shoe part that may face inward and towards a wearer's footwhen assembled into a shoe) and background surface may be manufactured(i.e., intentionally made) to comprise known contrasting colors.

Additional tools may be used to assist with recognizing a perimeter oroutline of a representation. For example, system 210 may compriselight-emitting devices 241 a and 241 b that illuminate the shoe partfrom various sources. As described with respect to FIG. 1A,light-emitting devices may be arranged in various positions throughoutsystem 210. For example, surface 229 may be illuminated with device 241a or backlit with light 241 b, thereby enhancing a contrast betweensurface 229 and part 224 to render part 224 more recognizable to the 2-Drecognition system. That is, if part 224 is illuminated or backlit whenimage 228 is captured, a better contrast may appear in image 228 betweenrepresentation 232 and other portions of the image. A full-spectrumlight may be used for enhancing part recognition of parts having variouscolors. Alternatively, a color of the light may be customized based on acolor of part 224 and/or the color of supply station and/or assemblystation. For example, a red light may be used to enhance a contrastbetween parts and a supply assembly station that are black or white.

Next, at step 316, image analyzer 216 a may determine a plurality ofreference features associated with the 2-D representation 232 depictedin image 228. For instance, the reference features may comprise a numberof spaced lines and/or points that define the outline or perimeter ofthe 2-D representation. The spacing between adjacent reference featuresmay be variable. For instance, the spacing between reference featuresfor smaller-sized shoe parts may be less than the spacing betweenreference features for larger-sized shoe parts to allow for moreprecision. Each reference feature may be comprised of a variable numberof pixels.

An identity of a boundary of the 2-D representation 232 may berecognized using various techniques. For example, shoe-partrepresentation 232 may be compared to various known or model shoe-partreferences 234-236, which are stored in shoe-part datastore 220 in orderto determine the identity of the shoe-part representation 232.

Shoe-part datastore 220 stores information 238, which is shown in anexploded view 240 for illustrative purposes. As an example, explodedview 240 depicts a plurality of known shoe-part references 234-236 thatmay be used to recognize the identity of the 2-D representation 232.Shoe-part references 234-236 may be associated with pre-determinedreference features (e.g., 242 and 244) as outlined above with respect toFIG. 1B, which may be used when assembling a respective shoe part into ashoe. Such reference features may be pre-determined based on variousfactors, such as a known position of a shoe part among an assembly ofshoe parts. For example, when incorporated into a shoe, shoe part 224 isassembled at a position with respect to shoe part 226. As such, thisposition may be measured and used to instruct shoe-manufacturingequipment on positioning and attachment of shoe part 224.

As depicted in FIG. 2, shoe-part references 234-236 form various 2-Dshapes. In an aspect of the invention, the pre-determined referencefeatures may comprise any number of features associated with theperimeter or outline of the shoe-part references 234-236. For example, areference feature may comprise a specified proportion between differentsides of the 2-D shape. As well, a reference feature may comprise ajunction point between two adjacent sides of the 2-D shape. Creatingpre-determined reference features along a perimeter of the shape canreduce variability that may be created when shoe parts are aligned andconnected.

The image analyzer 216 a may recognize an identity of the 2-Drepresentation 232 by identifying at least one shoe-part reference ofthe plurality of shoe-part references 234-236 that substantially matchesthe 2-D shoe-part representation 232. For example, the image analyzer216 a may recognize the identity of the 2-D shoe-part representation 232by identifying at least one pre-determined reference feature of ashoe-part reference that substantially matches the at least onereference feature of the 2-D representation 232.

Once a shoe-part representation (e.g., 232) is substantially matched toa known shoe-part reference (e.g., 234), the pre-determined referencefeature(s) may be used to analyze an image that depicts therepresentation. For example, image analyzer 216 a has retrieved arecognized entity 249 based on shoe-part reference 234, which wassubstantially matched to 2-D representation 232. As depicted, recognizedentity 249 has a boundary and pre-determined reference feature(s).Accordingly, when the descriptions of FIGS. 1B and 2 are collectivelyconsidered, an exemplary method may comprise various steps. For example,model references (e.g., 1012 a and 1014 a) and their correspondingpre-determined reference features (e.g., 1021 and 1022) are determinedand electronically maintained, such as in datastore 220. A recordedimage (e.g., 228 and 230) may then be substantially matched to a modelreference by substantially matching reference features of the recordedimage with pre-determined reference features of the model. Thisreference information may be mathematically depicted with respect to aknown reference system.

At step 318, a rotation of the representation (as depicted in the image)and pixel coordinates of the image are identified. To illustrate onemanner in which image analyzer 216 a utilizes recognized entity 249 toexecute step 318, information 250 is depicted in an exploded view 252.Exploded view 252 depicts image 254 that is identical to image 228. Forexample, image 254 and image 228 may be the same data, or image 254 maybe a copy of image 228. Image 254 is depicted respective to a coordinatesystem 256, which maps pixels of image 254. Recognized entity 249 isapplied to image 254, such as by substantially centering image 254within the boundaries of recognized entity 249 and aligning by referencefeature(s) 258. As such, pixel coordinates of image 254 can bedetermined that belong to coordinate system 252. In addition, a degreeof rotation (i.e., Θ) of the shoe-part representation (as depicted inimage 254) is determined by measuring an angle between reference lines260 and 262.

The pixel coordinates and degree of rotation that are extracted from theimage may be used to instruct part-transfer apparatus 212. That is,image 228 may be recorded by camera 214 a when shoe part 224 is oriented(i.e., positioned and rotated) somewhere in the 3-D space in whichpart-transfer apparatus 212 operates. Examples of positions at whichshoe part 224 may be located include a part supply station, an assemblystation, and/or held by part-transfer apparatus 212. Accordingly, whencertain inputs are provided, pixel coordinates of image 228 may beconverted by dimension converter 218 to a geometric coordinate 205 ofthe system represented by grid 225. Accordingly, in step 320 of method310 the pixel coordinates may be converted to a geometric coordinate.

Inputs utilized by dimension converter 218 may comprise measurementvalues describing system 210, camera 214 a, and part-transfer apparatus212. Examples of such measurement values are relative positions (i.e.,zero positions) of camera 214 a and of part-transfer apparatus 212; anumber of pixels of the X and Y coordinates of system 256; a distancebetween camera 214 a and part 224; a chip size of the CCD in camera 214a; a lens focal length; a field of view; a pixel size; and a resolutionper pixel. These inputs may vary depending on the capabilities of theequipment used in system 210 and some inputs may have a direct bearingon where equipment may be positioned within system 210. For example, thestrength of camera 214 a may have a bearing on where part 224 should bepositioned (relative to camera 214 a) when camera 214 a will record animage of part 224. To further illustrate a relationship between variousinputs used to convert a pixel coordinate to a geometric coordinate,FIG. 4 depicts a schematic diagram of a system with which an image maybe recorded and analyzed.

The geometric coordinate generated by dimension converter 218 can beused to report a position of shoe part 224 to part-transfer apparatus212. Moreover, the degree of rotation can be used to determine to whatextent shoe part 224 may need to be rotated by part-transfer apparatus212 in order to be properly aligned for subsequent manipulation (e.g.,attachment to another shoe part, cutting, painting, etc.). Accordingly,part-transfer apparatus 212 may comprise a part-pickup tool that enablespart-transfer apparatus 212 to acquire part 224 from a part-supply areaand temporarily hold part 224 while transferring part 224 to a newlocation. For example, part-transfer apparatus 212 may use a grippingstructure, suction, electromagnetic forces, surface tack, or any othermethodology to temporarily engage and move a shoe part.

Although the above 2-D recognition process is described by referencingshoe part 224 and image 228, a similar analysis may be used to identifyshoe part 226 and determine its orientation, thereby enablingpart-transfer apparatus 212 to account for part 226 when manipulatingpart 224. That is, information 270 is depicted in image analyzer 216 band is shown in an exploded view 272 for illustrative purposes. Explodedview 272 conveys that image 230 may be analyzed similar to image 228 todetermine an orientation (i.e., geometric coordinate and degree ofrotation) of part 226 based on reference feature(s) 279 and theta. Anynumber of shoe parts may be identified and/or positioned, eithersimultaneously or sequentially in accordance with the present invention.

Once respective geometric coordinates of part 224 and part 226 areknown, part-transfer apparatus 212 can pick up part 224 and move part224 to a part-position coordinate 203 that is relative to the geometriccoordinate of part 226. For example, FIG. 2 depicts multiple broken-lineviews of part-transfer apparatus 212 to illustrate a movement ofpart-transfer apparatus and a transfer of part 224. A part-positioncoordinate 203 refers to a coordinate in the geometric coordinate system(e.g., the system illustrated by grid 225) to which an attachment part(e.g., part 224) is transferred in order to be attached to a base part(e.g., part 226). For example, part-transfer apparatus 212 may transferpart 224 to geometric coordinate 203 to be attached to part 226.

A part-position coordinate 203 may be determined in various ways. Forexample, part 226 may be a base shoe part onto which part 224 isattached, such that a position of part 224 respective to part 226 (whenthe parts are assembled) is known. As such, the known position may bedetermined by retrieving a stored reference feature, which waspre-determined using a method similar to that described with respect toFIG. 1B. However, this position that is known may still be converted toa coordinate that is recognized by part-transfer apparatus 212 when part226 has been positioned within a coordinate system of part-transferapparatus 212. That is, outside of coordinate system 225, a positionrelative to part 226 at which part 224 is arranged is known, and isidentified by reference numeral 277 in datastore 220. This position isalso identified in exploded view 272 in which the position is identifiedas “part-position location for part 224.” When an orientation of part226 is determined, such as by executing method 310, the point 277 (alsodepicted in exploded view 272) that is respective to part 226 at whichpart 224 is arranged can be converted to a geometric coordinate 203within system 225, thereby calculating part-position coordinate 203.Accordingly, in an exemplary aspect, part-position 203 is converted to ageometric coordinate based in part on reference feature 1022, which wasdescribed with reference to FIG. 1B.

In a further aspect, once part-position point 203 is determined, part224 can be transferred to the part-position coordinate 203 based on thereference information determined with respect to part 224 (e.g., 1021 inFIG. 1B). For example, pixel coordinates and orientation may be derivedfrom image 228 (as described above) and may be converted to a geometriccoordinate (e.g., 205). Calculations may then be made to transfer part224 to point 203. For example, a virtual robot end effector may becreated based on the geometric data (e.g., 203 and 205) and may be movedfrom point 205 to point 203. While these steps are depicted graphicallyin FIG. 2 for illustrative purposes, these steps could also be executedmathematically by solving sequential conversion algorithms.

Accordingly, the above-described recognition process (e.g., method 310)may be used in many different scenarios within a shoe-manufacturingprocess. For example, once shoe part 224 has been positioned respectiveto shoe part 226, shoe part 224 can be attached to shoe part 226, suchas by stitching, adhering, and/or sonic welding. As such, in order toenable automation, a geometric coordinate 201 of the attachment point isalso determined. That is, once geometric coordinates of parts 224 and226 are known within coordinate system 225, geometric coordinates ofattachment locations can also be calculated.

An attachment-point coordinate 201 may be determined in various ways.For example, part 226 may be a base shoe part onto part 224 is attached.As such, a point of attachment onto base shoe part is known, but itstill may be converted to a coordinate that is recognized bypart-transfer apparatus 212. That is, outside of coordinate system 225,a point on part 226 at which part 224 will be attached is known, and isidentified by reference numeral 274 in datastore 220. When anorientation of part 226 is determined, such as by executing method 310,the point 274 (also depicted in exploded view 272) on part 226 at whichpart 224 is attached can be converted to a geometric coordinate 201within system 225. As such, an attachment process can be executed at thegeometric coordinate 201. As indicated above, although these steps aredepicted graphically in FIG. 2 for illustrative purposes, these stepscould also be executed mathematically by solving sequential conversionalgorithms.

In one aspect, part-transfer tool 212 also may have an attachmentdevice, which operates to attach part 224 to part 226. Exemplaryattachment devices are an ultrasonic welder, heat press, stitchingapparatus, or a device that accomplishes a respective method ofattachment. For instance, an ultrasonic welder may apply ultrasonicenergy through an ultrasonic-welding horn in order to attach in atemporary or permanent fashion parts 224 and 226.

The components of system 210 may be arranged in various configurationsto accomplish a wide range of shoe-manufacturing processes. In addition,there may be additional components arranged into a series of stations.For example, system 210 may be comprised of cameras in addition tocameras 214 a-b, as well as additional part-transfer apparatuses.Different types of cameras and/or part transfer apparatuses may becombined in accordance with the present invention. These additionaltools may be arranged at different positions along conveyor 222 to allowadditional parts to be added (e.g., added to the assembly of parts 224and 226) and to allow additional shoe-part manipulation.

Moreover, the cameras of system 210 may be arranged at differentpositions with respect to a shoe part. For example, as depicted in FIG.1A, cameras may be positioned above a shoe part, below a shoe part,horizontal to a shoe part, or at an angle away from a shoe part, so longas the camera position allows the geometric coordinate of the part to becalculated. One such camera position may be perpendicular to (i.e.,normal to) a viewing plane. However, the camera could be positioned atan angle from the viewing plane, so long as the angle is provided as aninput to the system when converting the representation orientation to ageometric coordinate. Accordingly, system 210 may be incorporated intolarger shoe-manufacturing processes.

A 2-D recognition system may be used at an initial stage to enablepart-transfer apparatus 212 to position a base shoe part onto a conveyoror other part-moving apparatus. A base shoe part refers to a shoe partonto which one or more other shoe parts may be attached, and a base shoepart may be constructed of a single part or a plurality of parts thathave been assembled. Accordingly, part 226 may be deemed a base shoepart onto which part 224 is attached. Parts transferred may also befoams, mesh, and/or adhesive layers, such as TPU films, ultimately usedto join other parts together. Further, component parts previouslyaffixed to one another in accordance with the present invention may betreated as a single part for subsequent identification transfer, etc.

Referring to FIG. 5, a system 510 is depicted in which a 2-Dpart-recognition system may be used at an initial manufacturing stage,such as when the base shoe part 526 is initially stored at a part-supplystation 580, which may be comprised of various configurations. Forexample, a part-supply station 580 may comprise a set of stacked baseshoe parts from which part-transfer apparatus 512 acquires a topmostbase shoe part. Alternatively, the part-supply station may have aconveyor 582 that transfers the base shoe part to a pickup location 584at which part-transfer apparatus 512 acquires the base shoe part. Aspreviously described, part-transfer apparatus 512 may have a part-pickuptool 585.

Prior to transferring base shoe part 526 to conveyor 596, a camera mayrecord an image of the base shoe part 526 to allow part-transferapparatus 512 to determine a geometric position and rotation of the baseshoe part 526. For example, a camera may record an image of the baseshoe part 526 when the base shoe part 526 is next-in-line to be acquiredby part-transfer apparatus 512—i.e., immediately prior to the base shoepart 526 being acquired by part-transfer apparatus 512 and when the baseshoe part 526 is at pickup location 584. The camera may be anabove-mounted camera 590 a-b that is mounted above, and perpendicularto, the base shoe part 526. As depicted in FIG. 5, an above-mountedcamera 590 a-b may be mounted either apart from (e.g., 590 a) or onto(e.g., 590 b) part-transfer apparatus 512.

Although part-transfer apparatus 512 is illustrated to have a certainconfiguration depicted in FIG. 5, part-transfer apparatus may have adifferent configuration, such as the configuration depicted in FIG. 1A,in which a camera mounted to the part-transfer apparatus may bepositionable directly above and perpendicular to base shoe part 526.Part-transfer apparatus 512 may also comprise a plurality ofarticulating arms that enable movement of a camera (or an acquired shoepart) to a desired angle or position.

Moreover, if the image is recorded while the base shoe part 526 is at apart-supply station (i.e., at location 584), a light-emitting device maybe arranged at various positions throughout system 510. For example, alight-emitting device 541 a may be positioned adjacent to orincorporated into the part-supply station 580 to provide a backlight tothe base shoe part 526. Also, a light-emitting device 541 b may bepositioned in a space that surrounds base shoe part, such that thelight-emitting device 541 b illuminates base shoe part 526 from a frontside.

Alternatively, part-transfer apparatus 512 may acquire base shoe part526 before an image is recorded and position the acquired base shoe partin front of a camera. For example, a below-mounted camera 592 may besecured near a floor surface, and part-transfer apparatus 512 mayposition the acquired base shoe part directly above, and perpendicularto, the below-mounted camera 512. Alternatively, part-transfer apparatus512 may position the acquired base shoe part directly below, andperpendicular to, above-mounted cameras 590 a or 594. As describedabove, although part-transfer apparatus 512 is illustrated to have acertain configuration depicted in FIG. 5, part-transfer apparatus mayhave a different configuration. For example, part-transfer apparatus 512may have the configuration depicted in FIG. 1A. In addition,part-transfer apparatus may be comprised of a plurality of articulatingarms.

If the image is recorded after the base shoe part 526 has been acquiredby part-transfer apparatus, a light-emitting device 541 c may bearranged at various positions. For example, a light-emitting device 541c may be incorporated into the part-transfer apparatus 512, such asbehind (or incorporated into) the part-pickup tool 585, therebyproviding a backlight to base shoe part 526. In addition, otherlight-emitting devices (e.g., 541 d) positions throughout system 510 mayilluminate a front side of a base shoe part that is acquired bypart-transfer apparatus 512

Once an image has been recorded, a geometric position and rotation ofthe base shoe part may be determined using the previously describedmethods (e.g., method 310). The geometric position and rotation may thenbe used to determine a position of the base shoe part when the base shoepart is transferred to conveyor 596. For example, part-transferapparatus 512 may execute a predetermined movement path each time ittransfers base shoe part 526 from a part-supply station 580, or from infront of a camera (e.g., 590 a, 592, or 594), to conveyor 596. As such,once the geometric position and rotation of the base shoe part areknown, the part-transfer apparatus may determine where the base shoepart will be positioned when the predetermined movement path isexecuted. Alternatively, a geometric position on conveyor 596 may bepredetermined, such that part-transfer apparatus 512 (or some computingdevice associated therewith) calculates a new movement path each time.That is, the new movement path extends from the calculated position ofthe base shoe part 526 (when the image is recorded) to the predeterminedposition on the conveyor 596. Computing device 532 may help executevarious operations, such as by analyzing images and providinginstructions to shoe-manufacturing equipment.

In another aspect, a 2-D recognition system may be used when base shoepart 526 has already been transferred to conveyor 596 in order todetermine a geometric position and rotation of base shoe part 526 as itis arranged on conveyor 596. As such, conveyor 596 may move base shoepart along an assembly line and to a position that is beneath anabove-mounted camera (e.g., 594). Once an image has been recorded by theabove-mounted camera and a position of base shoe part has beendetermined, other shoe parts may be transferred and attached to the baseshoe part.

As such, in a further aspect, a 2-D recognition system may be used afterthe initial stage to enable a part-transfer apparatus to position anattachment shoe part. An attachment shoe part refers to a shoe part thatis to be attached to a base shoe part. Accordingly, in FIG. 2 part 224may be deemed an attachment shoe part that is to be attached to shoepart 226.

Referring to FIG. 6, a system 610 is depicted in which a 2-D recognitionsystem may be used to position an attachment part 624, such as when theattachment shoe part 624 is initially stored at a part-supply station682, which may be arranged into various configurations. As previouslydescribed, a part-supply station 682 may comprise a set of stacked shoeparts from which part-transfer apparatus 612 acquires a topmostattachment shoe part. Alternatively, the part-supply station 682 may becomprised of a set of conveyors 682 a and 682 b, one of which transfersthe attachment shoe part 624 to a pickup location 684 at whichpart-transfer apparatus 612 may acquire the attachment shoe part 624.

As previously described, part-transfer apparatus 612 may have apart-pickup tool 685. Although part-transfer apparatus 612 isillustrated to have a certain configuration depicted in FIG. 6,part-transfer apparatus may have a different configuration, such as theconfiguration depicted in FIG. 1A, or a configuration comprising aplurality of articulating arms that enable movement of a camera (or anacquired shoe part) to a desired angle or position.

The attachment shoe part 624 may be provided at the supply station 682among a plurality of different attachment shoe parts (e.g., 606 and608), each of which may be attached to a respective portion of base shoepart 626. As such, 2-D recognition system may execute a part-selectionprotocol, which allows the system to identify and select a desiredattachment part.

In an exemplary part-selection protocol, the 2-D recognition system maybe programmed to follow a predetermined order of attachment parts—i.e.,attach first part 624, followed by second part 608, followed by thirdpart 606, etc. Accordingly, the 2-D recognition system may record imagesof all of the parts arranged among the plurality, identify each part(e.g., based on datastore 220), and determine a geometric location ofeach part as it is positioned at supply station 682. Once this positioninformation has been determined by the 2-D recognition system,part-transfer apparatus 612 may acquire and attach each part in thepredetermined order.

In another part-selection protocol, the 2-D recognition system may beprogrammed to transfer and attach a set of parts, regardless of theorder—i.e., attach first, second, and third parts in any order.Accordingly, once images of each part (e.g., 606, 608, and 624) havebeen analyzed to determine a geometric position, part-transfer apparatus612 may acquire the parts in a variety of orders, as long as all of theparts are transferred to the base part 626 at some point. Moreover, the2-D recognition system may be programmed to retrieve the parts that arepositioned in a manner that allows for the most efficient transfer fromthe supply station 682 to base shoe part 626. For example, if two firstparts 698 a and 698 b are provided at the supply station and one of thefirst parts 698 a is closer than the other first part 698 b (based onrespective geometric coordinates), the part-transfer apparatus 612 maybe instructed to pick up the closer first part 698 a instead of theother first part 698 b. Similarly, if a first part 698 a is rotated to adegree that may need less adjustment (relative to another first part 698b) in order to be attached to base part 626, the part-transfer apparatus612 may be instructed to pick up the first part 698 a. Computing device632 may help execute various operations, such as by executing certainsteps in a part-selection protocol, analyzing images, and providinginstructions to shoe-manufacturing equipment.

In another exemplary aspect, parts 606, 608, and 624 may be arranged atpart-pickup location 684 in a pre-determined configuration, such thatcoordinates of the pre-determined configuration may be provided toapparatus 612 to assist with part selection. That is, if a coordinate ofeach part 606, 608, and 624 is pre-determined based on how the group ofparts are to be arranged (prior to being picked up), then a coordinatemay not have to be calculated based on images. Or, a pre-determinedcoordinate may be used as a check to confirm that a calculatedcoordinate is accurate (e.g., within a threshold amount away from thepre-determined coordinate).

In a further aspect, a pre-determined arrangement of parts 606, 608, and624 at part-pickup location 684 may match an arrangement of the parts606, 608, and 624 when the parts are attached to base part 626. That is,each of parts 606, 608, and 624 may be spaced apart from one another androtated in a manner that matches a spacing and rotation of each partwhen attached to base part 626. As such, parts 606, 608, and 624 may bepicked up, placed, and/or attached as a collective group (i.e., morethan one at a time) in a manner that maintains the pre-determinedarrangement (i.e., maintains the spacing and rotation).

When an image is recorded of an attachment shoe part 624 to determine anorientation of the attachment shoe part 624, the camera may bepositioned in various locations. As previously described, if theattachment shoe part 624 is positioned at the supply station 682 whenthe image is captured, the camera (e.g., 690 b) may be coupled directlyto part-transfer apparatus 612, or may be an above-mounted camera 690 a.Camera 690 b or 690 a may be perpendicularly oriented from shoe part 624when the image is recorded. For example, part-transfer apparatus 612 maybe comprised of one or more articulating arms that position camera 690 babove and perpendicular to shoe part 624.

Moreover, light-emitting devices may be arranged throughout system 610to illuminate shoe part 624 when positioned at part-supply station 682.For example, a light-emitting device 641 a or 641 b may be positionedadjacent to, or integrated into, the supply station 682 in order tobacklight the attachment shoe parts positioned on conveyors 682 a and682 b. Also, light-emitting devices 641 c may be positioned in a spacesurrounding part-supply station 682 to illuminate a front side of shoepart 624.

If the attachment shoe part 624 is retained by part-transfer apparatus612 when the image is captured, the camera may be mounted remotely fromthe part-transfer apparatus 612, such as camera 690 a, 692, or 694. Insuch an arrangement, shoe-transfer apparatus 612 may position theattachment shoe part in front of (e.g., perpendicular to a field of viewof) camera 690 a, 692, or 694. Moreover, a light-emitting device 641 dmay be integrated into the part-transfer apparatus 612, such as behindthe part-pickup tool 685, in order to illuminate the acquired shoe partswhen the image is captured.

Although some of the above methods describe analyzing a single image todetermine an orientation, multiple images of a single part, which arerecorded by one or more cameras, may be analyzed to derive a set ofgeometric coordinates that are believed to accurately represent aposition of a shoe part. In such a system, the set of geometriccoordinates may be averaged or otherwise combined to arrive at a finalgeometric coordinate.

Referring now to FIG. 7, a flow diagram is depicted of a method 710 forpositioning a shoe part in an automated manner during ashoe-manufacturing process. In describing FIG. 7, reference is also bemade to FIG. 2. In addition, method 710, or at least a portion thereof,may be carried out when a computing device executes a set ofcomputer-executable instructions stored on computer storage media.

At step 712 an image (e.g., 228) may be received depicting atwo-dimensional representation (e.g., 232) of an attachment shoe part(e.g., 224), which is to be attached to a base shoe part (e.g., 226),wherein the two-dimensional representation of the attachment shoe partcomprises a plurality of reference features 258. At step 714, pixelcoordinates of the image (e.g., coordinate of system 256) are identifiedthat correspond to the reference features. Step 716 converts the pixelcoordinates of the image to a geometric coordinate (e.g., 205) of ageometric coordinate system (e.g., 225), which maps a three-dimensionalspace within which the attachment shoe part (e.g., 224) is positionedand a part-transfer apparatus (e.g., 212) operates. Further, at step718, another geometric coordinate (e.g., 203) of the geometriccoordinate system (e.g., 225) is determined by analyzing a differentimage (e.g., 230) depicting a two-dimensional representation (e.g., 233)of the base shoe part (e.g., 226) to which the attachment shoe part(e.g., 224) will be attached. Step 720 transfers, by the part-transferapparatus (e.g., 212), the attachment shoe part (e.g., 224) to the othergeometric coordinate (e.g., 203), thereby moving the attachment shoepart to a location in the three-dimensional space at which theattachment shoe part is to be attached to the base shoe part.

Referring now to FIG. 8, another flow diagram is depicted of a method810 for positioning a shoe part in an automated manner during ashoe-manufacturing process. In describing FIG. 8, reference is also bemade to FIG. 2. In addition, method 810, or at least a portion thereof,may be carried out when a computing device executes a set ofcomputer-executable instructions stored on computer storage media.

At step 812 an image (e.g., 228) is received depicting a two-dimensionalrepresentation (e.g., 232) of an attachment shoe part (e.g., 224), whichis to be attached to a base shoe part (e.g., 226), wherein thetwo-dimensional representation of the attachment shoe part comprises atleast one reference feature 258. At step 814, pixel coordinates of theimage (e.g., coordinate of system 256) are identified that correspond tothe at least one reference feature 258. Step 816 converts the pixelcoordinates of the image to a geometric coordinate (e.g., 205) of ageometric coordinate system (e.g., 225), which maps a three-dimensionalspace within which the attachment shoe part (e.g., 224) is positionedand a part-transfer apparatus (e.g., 212) operates. Furthermore, step818 determines a plurality of other geometric coordinates (e.g., 203 and202) in the geometric coordinate system by analyzing a different image(e.g., 230) depicting a two-dimensional representation (e.g., 233) ofthe base shoe part (e.g., 226) to which the attachment shoe part (e.g.,224) will be attached. The plurality of other geometric coordinates maycomprise a part-position coordinate (e.g., 203) and a part-attachmentcoordinate (e.g., 201). Step 820 transfers, by the part-transferapparatus, the attachment shoe part (e.g., 224) to the part-positioncoordinate (e.g., 203), and step 822 attaches the attachment shoe partto the base part at the part-attachment coordinate (e.g., 201).

The 2-D recognition system described above may also be used for qualitycontrol purposes. For instance, the 2-D recognition system may allow fordetection of a mismatched attachment part in a set of matching stackedattachment parts. Further, the 2-D recognition system may also enablequality control of shoe-part positioning to ensure position placementaccuracy.

As described above, our technology may comprise, among other things, amethod, a system, or a set of instructions stored on one or morecomputer-readable media. Information stored on the computer-readablemedia may be used to direct operations of a computing device, and anexemplary computing device 900 is depicted in FIG. 9. Computing device900 is but one example of a suitable computing system and is notintended to suggest any limitation as to the scope of use orfunctionality of invention aspects. Neither should the computing system900 be interpreted as having any dependency or requirement relating toany one or combination of components illustrated. Moreover, aspects ofthe invention may also be practiced in distributed computing systemswhere tasks are performed by separate or remote-processing devices thatare linked through a communications network.

Computing device 900 has a bus 910 that directly or indirectly couplesthe following components: memory 912, one or more processors 914, one ormore presentation components 916, input/output ports 918, input/outputcomponents 920, and an illustrative power supply 922. Bus 910 representswhat may be one or more busses (such as an address bus, data bus, orcombination thereof). Although the various blocks of FIG. 9 are shownwith lines for the sake of clarity, in reality, delineating variouscomponents is not so clear, and metaphorically, the lines would moreaccurately be grey and fuzzy. For example, processors may have memory.

Computing device 900 typically may have a variety of computer-readablemedia. By way of example, and not limitation, computer-readable mediamay comprises Random Access Memory (RAM); Read Only Memory (ROM);Electronically Erasable Programmable Read Only Memory (EEPROM); flashmemory or other memory technologies; CDROM, digital versatile disks(DVD) or other optical or holographic media; magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,carrier wave or any other medium that can be used to encode desiredinformation and be accessed by computing device 900.

Memory 912 is comprised of tangible computer-storage media in the formof volatile and/or nonvolatile memory. Memory 912 may be removable,nonremovable, or a combination thereof. Exemplary hardware devices aresolid-state memory, hard drives, optical-disc drives, etc.

Computing device 900 is depicted to have one or more processors 914 thatread data from various entities such as memory 912 or I/O components920. Exemplary data that is read by a processor may be comprised ofcomputer code or machine-useable instructions, which may becomputer-executable instructions such as program modules, being executedby a computer or other machine. Generally, program modules such asroutines, programs, objects, components, data structures, etc., refer tocode that perform particular tasks or implement particular abstract datatypes.

Presentation component(s) 916 present data indications to a user orother device. Exemplary presentation components are a display device,speaker, printing component, light-emitting component, etc. I/O ports918 allow computing device 900 to be logically coupled to other devicesincluding I/O components 920, some of which may be built in.

In the context of shoe manufacturing, a computing device 900 may be usedto determine operations of various shoe-manufacturing tools. Forexample, a computing device may be used to control a part-pickup tool ora conveyor that transfers shoe parts from one location to another. Inaddition, a computing device may be used to control a part-attachmentdevice that attaches (e.g., welds, adheres, stitches, etc.) one shoepart to another shoe part.

B. Assembling Shoe Parts Using a Multi-Functional Manufacturing Tool

Aspects of the present invention also relate to systems, methods, andapparatus for a manufacturing tool. The manufacturing tool is highlyadaptable for use with a variety of materials, a variety of shapes, avariety of part sizes, a variety of manufacturing processes, and avariety of locations within an automated manufacturing system. This highlevel of adaptability provides a manufacturing tool that is a criticalcomponent in an automated manufacturing process. To accomplish this, themanufacturing tool is comprised of a vacuum tool and an ultrasonicwelder as a unified manufacturing tool that is able to be manipulatedfrom a single positional member. The manufacturing tool may be used topick and position a manufacturing part such as a shoe part that is thenwelded or tacked with the associated ultrasonic welder.

FIG. 10 depicts a top-down view of an exemplary vacuum tool 3100, inaccordance with embodiments of the present invention. In variousaspects, the vacuum tool 3100 may also be referred to as avacuum-powered part holder, a manufacturing tool, a multi-functionalmanufacturing tool, a part-pickup tool/apparatus, and/or a part-transfertool/apparatus; all terms are used interchangeably herein. For example,the vacuum tool 3100 may be useable in an automated (or partiallyautomated) manufacturing process for the movement, positioning, and/ormaintaining of one or more parts. The parts manipulated by the vacuumtool 3100 may be rigid, malleable, or any combination of characteristics(e.g., porous, non-porous). In an exemplary aspect, the vacuum tool 3100is functional for picking and placing a part constructed, at least inpart, of leather, polymers, textiles, rubber, foam, mesh, and/or thelike.

The material to be manipulated by a vacuum tool may be of any type. Forexample, it is contemplated that a vacuum tool described herein isadapted for manipulating (e.g., picking and placing) flat, thin, and/orlightweight parts of various shapes, materials, and other physicalcharacteristics (e.g. pattern cut textiles, non-woven materials, mesh,plastic sheeting material, foams, rubber). Therefore, unlikeindustrial-scaled vacuum tools functional for manipulating a heavy,rigid, or non-porous material, the vacuum tools provided herein are ableto effectively manipulate a variety of materials (e.g., light, porous,flexible).

The vacuum tool 3100 is comprised of a vacuum generator 3102. The vacuumgenerator generates a vacuum force (e.g., low pressure gradient relativeto ambient conditions). For example, the vacuum generator 3102 mayutilize traditional vacuum pumps operated by a motor (or engine). Thevacuum generator 3102 may also utilize a venturi pump to generate avacuum. Further yet, it is contemplated that an air amplifier, which isalso referred to as a coand{hacek over (a)} effect pump, is alsoutilized to generate a vacuum force. Both the venturi pump and thecoand{hacek over (a)} effect pump operate on varied principles ofconverting a pressurized gas into a vacuum force effective formaintaining a suction action. While the following disclosure will focuson the venturi pump and/or the coand{hacek over (a)} effect pump, it iscontemplated that the vacuum generator 3102 may also be a mechanicalvacuum that is either local or remote (coupled by way of tubing, piping,and the like) to the vacuum tool 3100.

The vacuum tool 3100 of FIG. 1 is also comprised of a vacuum distributor3110. The vacuum distributor 3110 distributes a vacuum force generatedby the vacuum generator 3102 across a defined surface area. For example,a material to be manipulated by the vacuum tool 3100 may be a flexiblematerial of several square inches in surface area (e.g., a leatherportion for a shoe upper). As a result of the material being at leastsemi-flexible, the vacuum force used to pick up the part may beadvantageously dispersed across a substantial area of the part. Forexample, rather than focusing a suction effect on a limited surface areaof a flexible part, which may result in bending or creasing of the partonce support underneath of the part is removed (e.g., when the part islifted), dispersing the suction effect across a greater area may inhibitan undesired bending or creasing of the part. Further, it iscontemplated that a concentrated vacuum (non-dispersed vacuum force) maydamage a part once a sufficient vacuum is applied. Therefore, in anaspect of the present invention, the vacuum force generated by thevacuum generator 3102 is distributed across a larger potential surfacearea by way of the vacuum distributor 3110.

In an exemplary aspect, the vacuum distributor 3110 is formed from asemi-rigid to rigid material, such as metal (e.g., aluminum) orpolymers. However, other materials are contemplated. The vacuum tool3100 is contemplated as being manipulated (e.g. moved/positioned) by arobot, such as a multi-axis programmable robot in response toinstructions received from, for example, a part-recognition system. Assuch, limitations of a robot may be taken into consideration for thevacuum tool 3100. For example, weight of the vacuum tool 3100 (and/or amanufacturing tool 3310 to be discussed hereinafter) may be desired tobe limited in order to limit the potential size and/or costs associatedwith a manipulating robot. Utilizing weight as a limiting factor, it maybe advantageous to form the vacuum distributor in a particular manner toreduce weight while still achieving a desired distribution of the vacuumforce.

Other consideration may be evaluated in the design and implementation ofthe vacuum tool 3100. For example, a desired level of rigidity of thevacuum tool 3100 may result in reinforcement portions andmaterial-removed portions, as will be discussed with respect to FIG. 26hereinafter, being incorporated into the vacuum tool 3100.

The vacuum distributor 3110 is comprised of an exterior top surface 3112and an exterior side surface 3116. FIG. 10 depicts a vacuum distributorwith a substantially rectangular footprint. However, it is contemplatedthat any footprint may be utilized. For example, a non-circularfootprint may be utilized. A non-circular footprint, in an exemplaryaspect, may be advantageous as providing a larger useable surface areafor manipulating a variety of part geometries. Therefore, the use of anon-circular footprint may allow for a greater percentage of thefootprint to be in contact with a manipulated part as compared to acircular footprint. Also with respect to shape of a vacuum tool 3100beyond the footprint, it is contemplated, as will be discussedhereinafter, that any three-dimensional geometry may be implemented forthe vacuum distributor 3110. For example, an egg-like geometry, apyramid-like geometry, a cubical-like geometry, and the like may beutilized.

The exemplary vacuum distributor 3110 of FIG. 10 is comprised of theexterior top surface 3112 and a plurality of exterior side surfaces3116. The vacuum distributor 3110 also terminates at edges resulting ina first side edge 3128, a second parallel side edge 3130, a front edge3132, and an opposite parallel back edge 3134.

FIG. 10 depicts a cutline 12-12 demarking a parallel view perspectivefor FIG. 11. FIG. 11 depicts a front-to-back perspective cut view thatis parallel along cut line 12-12 of the vacuum tool 3100, in accordancewith aspects of the present invention. FIG. 11 depicts, among otherfeatures, a vacuum distribution cavity 3140 and a vacuum plate 3150(also sometimes referred to as the “plate” herein). The vacuumdistributor 3110 and the plate 3150, in combination, define a volume ofspace forming the vacuum distribution cavity 3140. The vacuumdistribution cavity 3140 is a volume of space that allows for theunobstructed flow of gas to allow for an equalized dispersion of avacuum force. In an exemplary aspect, the flow of gas (e.g., air) fromthe plate 3150 to the vacuum generator 3102 is focused through theutilization of angled interior side surface(s) 3118. As depicted in FIG.11, there are four primary interior side surfaces, a first interior sidesurface 3120 (not shown), a second interior side surface 3122, a thirdinterior side surface 3124, and a fourth interior side surface 3126 (notshown). However, it is contemplated that other geometries may beutilized.

The interior side surfaces 3118 extend from the interior top surface3114 toward the plate 3150. In an exemplary aspect, an obtuse angle 3142is formed between the interior top surface and the interior sidesurfaces 3118. The obtuse angle 3142 provides an air vacuum distributioneffect that reduces internal turbulence of air as it passes from theplate 3150 toward a vacuum aperture 3138 serving the vacuum generator3102. By angling the approach of air as it enters the vacuum aperture3138, a reduced amount of material may be utilized with the vacuumdistributor 3110 (e.g., resulting in a potential reduction in weight)and the flow of air may be controlled through a reduction in airturbulence. An angle 3144 may also be defined by the intersection of theinterior side surfaces 3118 and the plate 3150.

The plate 3150, which will be discussed in greater detail in FIGS. 15-24hereinafter, has an interior plate surface 3152 (i.e., top surface) andan opposite exterior plate surface 3158 (i.e., bottom surface). Theexterior plate surface 3158 is adapted for contacting a part to bemanipulated by the vacuum tool 3100. For example, the plate 3150 ingeneral, or the exterior plate surface 3158 in particular, may be formedfrom a non-marring material. For example, aluminum or a polymer may beused to form the plate 3150 in whole or in part. Further, it iscontemplated that the plate 3150 is a semi-rigid or rigid structure toresist forces exerted on it from the vacuum generated by the vacuumgenerator 3102. Therefore, the plate 3150 may be formed of a materialhaving a sufficient thickness to resist deforming under pressurescreated by the vacuum generator 3102. Additionally, it is contemplatedthat the plate 3150 is formed from a material that conforms, in part, toan item to be manipulated. For example, the plate 3150 may beconstructed from a mesh-like material having a plurality of aperturesdefined by voids in the mesh-like material (e.g., textile mesh, metalmesh).

When used in combination, the vacuum generator 3102, the vacuumdistributor 3110, and the plate 3150, the vacuum tool 3100 is functionalto generate a suction force that draws a material towards the exteriorplate surface 3158 (also referred to as a manufacturing-part-contactingsurface) where the material is maintained against the plate 3150 untilthe force applied to the material is less than a force repelling (e.g.,gravity, vacuum) the material from the plate 3150. In use, the vacuumtool 3100 is therefore able to approach a part, generate a vacuum forcecapable of temporarily maintaining the part in contact with the plate3150, move the vacuum tool 3100 and the part to a new location, and thenallow the part to release from the vacuum tool 3100 at the new position(e.g., at a new location, in contact with a new material, at a newmanufacturing process, and the like).

FIG. 12 depicts a front-to-back view of the vacuum tool 3100 along thecutline 12-12 of FIG. 10, in accordance with aspects of the presentinvention. In particular, FIG. 12 provides a cut view of the vacuumgenerator 3102. As will be discussed in greater detail with respect toFIG. 13, the vacuum generator 3102, in the exemplary aspect, is an airamplifier utilizing a coand{hacek over (a)} effect to generate a vacuumforce.

In this example, air is drawn from the exterior plate surface 3158through a plurality of apertures 3160 through the plate 3150 to thevacuum distribution cavity 3140. The vacuum distribution cavity 3140 isenclosed between the vacuum distributor 3110 and the plate 3150, suchthat if the plate 3150 is a non-porous (i.e., lacked the plurality ofapertures 3160) surface, then an area of low pressure would be generatedin the vacuum distribution cavity 3140 when the vacuum generator 3102 isactivated. However, returning to the example including the plurality ofapertures 3160, the air is drawn into the vacuum distribution cavity3140 towards the vacuum aperture 3138, which then allows the air to bedrawn into the vacuum generator 3102.

FIG. 13 identifies a zoomed view of the vacuum generator 3102 depictedin FIG. 12. FIG. 13 depicts a focused view of the vacuum generator 3102as cut along the cutline 12-12 from FIG. 10, in accordance with aspectsof the present invention. The vacuum generator depicted in FIG. 13 is acoand{hacek over (a)} effect (i.e., air amplifier) vacuum pump 3106. Thecoand{hacek over (a)} effect vacuum pump injects pressurized air at aninlet 3103. The inlet 3103 directs the pressurized air through aninternal chamber 3302 to a sidewall flange 3304. The pressurized air,utilizing the coand{hacek over (a)} effect, curves around the sidewallflange 3304 and flows along an internal sidewall 3306. As a result ofthe pressurized air movement, a vacuum force is generated in the samedirection as the flow of the pressurized air along the internal sidewall3306. Consequently, a direction of suction extends up through the vacuumaperture 3138.

FIG. 14 depicts an exemplary plate 3150 comprised of the plurality ofapertures 3160, in accordance with aspects of the present invention.While the plate 3150 is illustrated as having a rectangular footprint,as previously discussed, it is contemplated that any geometry may beimplemented (e.g., circular, non-circular) depending, in part, on thematerial to be manipulated, a robot or positional member controlling thevacuum tool 3100, and/or components of the vacuum tool 3100.

The plurality of apertures 3160 may be defined, at least in part, by ageometry (e.g., circular, hatch, bulbous, rectangular), size (e.g.,diameter, radius (e.g., radius 3167), area, length, width), offset(e.g., offset 3169) from elements (e.g., distance from outer edge,distance from a non-porous portion), and pitch (e.g., distance betweenapertures (e.g., pitch 3168)). The pitch of two apertures is defined asa distance from a first aperture (e.g., first aperture 3162) to a secondaperture (e.g., second aperture 3164). The pitch may be measured in avariety of manners. For example, the pitch may be measured from theclosest two points of two apertures, from the surface area center of twoapertures (e.g., centre of circular apertures), and/or from a particularfeature of two apertures.

Depending on desired characteristics of a vacuum tool, the variablesassociated with the apertures may be adjusted. For example, a non-porousmaterial of low density may not require much vacuum force to maintainthe material in contact with the vacuum tool under normal operatingconditions. However, a large porous mesh material may, on the otherhand, require a significant amount of vacuum force to maintain thematerial against the vacuum tool under normal operating conditions.Therefore, to limit the amount of energy placed into the system (e.g.,amount of pressurized air to operate a coand{hacek over (a)} effectvacuum pump, electricity to operate a mechanical vacuum pump) anoptimization of the apertures may be implemented.

For example, a variable that may be sufficient for typical materialshandled in a footwear, apparel, and the like industry may include, butnot be limited to, apertures having a diameter between 0.5 and 5millimeters (mm), between 1 mm and 4 mm, between 1 mm and 3 mm, 1.5 mm,2 mm, 2.5 mm, 3 mm, and the like. However, larger and smaller diameter(or comparable surface area) apertures are contemplated. Similarly, thepitch may range between 1 mm and 8 mm, between 2 mm and 6 mm, between 2mm and 5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 5.5 mm, 6 mm, and thelike. However, larger and smaller pitch measurements are contemplated.

Additionally, it is contemplated that a variable size and a variablepitch may be implemented in aspects of the present invention. Forexample, a compound part composed of both a porous material portion anda non-porous material portion may utilize different variables toaccomplish the same level of manipulation. In this example, variablesthat lead to a reduction in necessary vacuum force in an area to becontacted by the non-porous material and variables that lead to highervacuum forces in an area to be contacted by the porous material may beimplemented. Further, a vision system or other part-identificationsystem may be used in conjunction to further ensure a proper placementof the material with respect to the plurality of apertures.Additionally, it is contemplated that a relationship between pitch andsize may be utilized to locate the plurality of apertures. For example,a pitch from a larger-sized aperture may be greater than a pitch from asmaller-sized aperture (or vice versa).

An additional variable is the offset. In an exemplary aspect, the offsetis a distance of an aperture from an outside edge of the plate 3150.Different apertures may have different offsets. Further different edgesmay implement different offsets. For example an offset along a frontedge may be different from an offset along a side edge. The offset mayrange from no offset to 8 mm (or more). In practice, an offset rangingfrom 1 mm to 5 mm may accomplish characteristics of exemplary aspects ofthe present invention.

The plurality of apertures 3160 may be formed in the plate 3150utilizing a number of manufacturing techniques. For example aperturesmay be punched, drilled, etched, carved, melted, and/or cut from theplate 3150. In an exemplary embodiment, the plate 3150 is formed from amaterial that is responsive to laser cutting. For example polymer-basedmaterials and some metal-based materials may be used in conjunction withlaser cutting of the plurality of apertures.

FIGS. 15-24 provide exemplary aperture variable selections similar tothat discussed with respect to FIG. 14, in accordance with aspects ofthe present invention. The following examples are not intended to belimiting, but instead exemplary in nature. FIG. 15 depicts non-circularapertures having a first offset of 5 mm and a second offset of 8 mm anda pitch of 7 mm. FIG. 16 depicts circular apertures having an offset andpitch of 5 mm with a diameter of 2 mm. FIG. 17 depicts circularapertures having a diameter of 1 mm, a pitch of 2 mm, and offsets of 4mm and 5 mm. FIG. 18 depicts circular apertures having a diameter of 2mm, a pitch of 4 mm, and offsets of 5 mm and 4 mm. FIG. 19 depictsexemplary geometric apertures having a pitch of 4 mm and offsets of 5mm. FIG. 20 depicts circular apertures having a diameter of 1 mm, apitch of 4 mm, and offsets of 5 mm and 4 mm. FIG. 21 depicts circularapertures having a diameter of 1 mm, a pitch of 5 mm, and offsets of 5mm. FIG. 22 depicts circular apertures having a diameter of 1.5 mm, apitch of 4 mm, and offsets of 5 mm and 4 mm. FIG. 23 depicts circularapertures having a diameter of 1.5 mm, a pitch of 3 mm, and offsets of 4mm. FIG. 24 depicts circular apertures having a diameter of 2 mm, apitch of 3 mm, and offsets of 5 mm and 4 mm. As previously discussed, itis contemplated that shape, size, pitch, and offset may be altereduniformly or variably in any combination to achieve a desired result.

FIG. 25 depicts an exploded view of a manufacturing tool 3310 comprisedof a vacuum tool 3100 and an ultrasonic welder 3200, in accordance withaspects of the present invention. Unlike the vacuum tool 3100 discussedwith respect to FIGS. 10 and 11, the vacuum tool 3100 of FIG. 25incorporates a plurality of vacuum generators 3102, vacuum distributors3110, and vacuum distribution cavities 3140 into a unified vacuum tool3100. As will be discussed hereinafter, advantages may be realized bythe ability to selectively activate/deactivate vacuum force inindividual portions of the vacuum tool 3100. Additionally, a greatercontrol of continuous vacuum force may be achieved by having segregatedportions of the vacuum tool 3100.

The manufacturing tool 3310 also is comprised of a coupling member 3300.The coupling member 3300 is a feature of the manufacturing tool 3310 (orthe vacuum tool 3100 or the ultrasonic welder 3200 individually)allowing a positional member (not shown) to manipulate the position,attitude, and/or orientation of the manufacturing tool 3310. Forexample, the coupling member 3300 may allow for the addition of themanufacturing tool to a computer-numerically-controlled (CNC) robot thathas a series of instructions embodied on a non-transitorycomputer-readable medium, that when executed by a processor and memory,cause the CNC robot to perform a series of steps. For example, the CNCrobot may control the vacuum generator(s) 3102, the ultrasonic welder3200, and/or the position to which the manufacturing tool 3310 islocated in response to instructions received from a part-recognitionsystem. The coupling member 3300 may, therefore, allow for the temporaryor permanent coupling of the manufacturing tool 3310 to a positionalmember, such as a CNC robot.

As was previously discussed, aspects of the present invention may formportions of the manufacturing tool 3310 with the intention of minimizingmass. As such, the plurality of vacuum distributors 3110 of FIG. 25include reduced material portions 3113. The reduced material portions3113 eliminate portions of what could otherwise be a uniform exteriortop surface. The introduction of reduced material portions 3113 reducesweight of the manufacturing tool 3310 to allow for a potentially smallerpositional member to be utilized, which may save on space and costs.Additional locations for reduced material portions 3113 are contemplatedabout the vacuum tool 3100 (e.g., side, bottom, top).

However, aspects of the present invention may desire to remain a levelof rigidity of the plurality of vacuum distributors 3110 as supported bya single coupling member 3300. To maintain a level of rigidity whilestill introducing the reduced material portions 3113, reinforcementportions 3115 may also be introduced. For example, reinforcementportions 3115 may extend from one vacuum distributor 3110 to anothervacuum distributor 3110. Further yet, it is contemplated that in aspectsof the present invention, reinforcement portions 3115 may be includedproximate to the coupling member 3300 for a similar rationale.

The plate 3150 is separated from the plurality of vacuum distributors3110 in FIG. 25 for illustrative purposes. As a result, an interiorplate surface 3152 is viewable. Traditionally, the interior platesurface 3152 is mated with a bottom portion of the plurality of vacuumdistributors 3110, forming an air-tight bond.

The vacuum tool 3100 is comprised of a plurality of vacuum generators3102, vacuum distributors 3110, and associated vacuum distributioncavities 3140. It is contemplated that any number of each may beutilized in a vacuum tool 3100. For example, it is contemplated that 10,8, 6, 4, 2, 1, or any number of units may be combined to form a cohesivevacuum tool 3100. Further, any footprint may be formed. For example,while a rectangular footprint is depicted in FIG. 25, it is contemplatedthat a square, triangular, circular, non-circular, part-matching shape,or the like may instead be implemented (e.g., the units may be modularsuch that depending on the material to be manipulated additional unitsmay be added or removed from the vacuum tool 3100. A coupling mechanismmay couple a first vacuum distributor 3110 with one or more additionalvacuum distributors 3110 to form the vacuum tool 3100). Additionally,the size of the vacuum generator 3102 and/or the vacuum distributor 3110may be varied (e.g., non-uniform) in various aspects. For example, in anexemplary aspect, where a greater concentration of vacuum force isneeded for a particular application, a smaller vacuum distributor may beutilized, and where a less concentrated vacuum force is needed, a largervacuum distributor may be implemented.

FIGS. 25-34 depict exemplary manufacturing tools 3310; however, it isunderstood that one or more components may be added or removed from eachaspect. For example, each aspect is comprised of an ultrasonic welder3200 and a vacuum tool 3100, but it is contemplated that the ultrasonicwelder 3200 may be eliminated all together. Similarly, it iscontemplated that one or more additional ultrasonic welders 3200 may beimplemented in conjunction with the various aspects. Further, it iscontemplated that additional features may also be incorporated. Forexample, part-recognition systems, adhesive applicators (e.g., spray,roll, hot-melt, and other application methods), mechanical fasteningcomponents, pressure applicators, curing devices (e.g., ultravioletlight, infrared light, heat applicators, and chemical applicators),lasers, heat welders, arc welders, microwaves, other energyconcentrating fastening devices, and the like may also be incorporatedin whole or in part in exemplary aspects. For example, any of theabove-referenced fastening tools (e.g., adhesive applicators, mechanicalfasteners, welders, and the like) may be used in addition to or insteadof an ultrasonic welder as discussed herein. Therefore, aspectscontemplate alternative fastening tools used in conjunction with one ormore vacuum tools.

The ultrasonic welder 3200, in an exemplary aspect, is comprised of astack comprised of an ultrasonic welding horn 3210 (may also be referredto as a sonotrode), a converter 3220 (may also be referred to as apiezoelectric transducer), and a booster (not labeled). The ultrasonicwelder 3200 may further be comprised of an electronic ultrasonicgenerator (may also be referred to as a power supply) and a controller.The electronic ultrasonic generator may be useable for delivering ahigh-powered alternating current signal with a frequency matching theresonance frequency of the stack (e.g., horn, converter, and booster).The controller controls the delivery of the ultrasonic energy from theultrasonic welder to one or more parts.

Within the stack, the converter converts the electrical signal receivedfrom the electronic ultrasonic generator into a mechanical vibration.The booster modifies the amplitude of the vibration from the converter.The ultrasonic welding horn applies the mechanical vibration to the oneor more parts to be welded in order to attach the one or more parts. Theattachment may be temporary or permanent. For example, temporaryattachment may be utilized to hold parts in place in anticipation ofadditional parts being added and/or attached. The ultrasonic weldinghorn is comprised of a distal end 3212 adapted for contacting a part.For example, the distal end 3212 may be formed so as to effectivelytransmit the mechanical vibration to the part while limiting thenecessary time, pressure, and/or surface area necessary for a particularweld. For example, the distal end may be adapted to result in a weldinghead spot size of a particular size for the materials to be welded. Theultrasonic welding head spot size may be in a diameter range from 1 mmto 8 mm, or in particular at/about 4 mm, 4.5 mm, 5 mm, 5.5 mm, 6 mm,and/or 6.5 mm in diameter. Further, a variety ultrasonic weldingfrequencies may be implemented, such as 15 kHz to 70 kHz. In anexemplary aspect, the welding frequency may be 15 kHz to 35 kHz, 25 kHzto 30 kHz, 26 kHz, 27 kHz, 28 kHz, and/or 29 kHz. Various other powerutilization variables may be altered. For example, power consumption mayalso include wattage of the ultrasonic welder. The wattage may beadjusted based on the material, time, pressure, thickness, weldpenetration, etc. In an exemplary aspect, the wattage may be about 300watts.

The ultrasonic welder 3200 may be positioned at a plurality of locationsrelative to the vacuum tool 3100. For example, the ultrasonic welder maybe located at any location along the perimeter of the vacuum tool 3100.Further, it is contemplated that the ultrasonic welder 3200 is offsetfrom the perimeter of the vacuum tool 3100 at any distance. In anexemplary aspect, the ultrasonic welder 3200 is located along theperimeter proximate the coupling member 3300 to minimize movement of themanufacturing tool 3310 when transitioning from vacuum to welding.Further, it is contemplated that a plurality of ultrasonic welders 3200are utilized at a variety of locations about the vacuum tool 3100 tofurther reduce travel time of the manufacturing tool 3310. Further yet,it is contemplated that one or more ultrasonic welding tools areintegrated into the vacuum tool 3100. For example, an ultrasonic weldermay be integrated at a location between two discrete vacuum distributors(e.g., location of reduced material portions 3113); such that anultrasonic welder 3200 may extend from a top surface of the vacuum tool3100 through to the exterior plate surface 3158. Therefore, it iscontemplated that any fastening tool (such as an ultrasonic welder) mayextend through the top surface of the vacuum tool through the exteriorplate 3158 at any location and at any orientation relative to the vacuumtool. As will be discussed in further detail with respect to FIG. 34, abiasing mechanism may also be implemented to allow portions of thevacuum tool 3100 to apply a greater compressive force than utilized bythe ultrasonic welder 3200 (e.g., to provide stabilization of the partsto be welded).

FIG. 26 depicts a top-down view of the manufacturing tool 3310previously depicted in FIG. 25, in accordance with aspects of thepresent invention. The top perspective of FIG. 26 provides an exemplaryview of a potential orientation of a plurality of vacuum distributors3110 to form a vacuum tool 3100. As will be discussed hereinafter withrespect to FIG. 29, various vacuum generator 3102/vacuum distributor3110 combinations may be selectively activated and/or deactivated tomanipulate particular parts.

FIG. 27 depicts a side-perspective view of the manufacturing tool 3310previously depicted in FIG. 25, in accordance with aspects of thepresent invention. The distal end 3212 of the horn 3210 extends below aplane defined by the exterior plate surface 3158. As a result of thedistal end 3212 extending beyond the plane, the distal end 3212 maycontact material without interference from the vacuum tool 3100 portionof the manufacturing tool 3310. However, it is contemplated that thedistal end 3212 extends approximately even with the exterior platesurface 3158 plane. Further, it is contemplated that the distal end 3212does not extend through the plane defined by the exterior plate surface3158 plane. In this example, it is contemplated that the vacuum tool3100 is moveably coupled to the coupling member allowing the exteriorplate surface 3158 plane to move relative to the distal end 3212 (e.g.,biasing mechanism, such as springs and/or pneumatics, may allow theexterior plate surface 3158 plane to move upwards once a sufficientpressure is applied to the exterior plate surface 3158). Further yet, itis contemplated that the distal end 3212 (and/or the ultrasonic welder3200 in general) is oriented on the manufacturing tool 3310 such that arotation about an axis by the positional member alters a materialmanipulating plane from that defined by the exterior plate surface 3158plane to a plane defined by the distal end 3212 (e.g., the vacuum tool3100 is rotated from being parallel to the materials being manipulateduntil the ultrasonic welder 3200 is perpendicular (or any acceptableangle) to the material to be welded). Stated differently, it iscontemplated that instead of positioning the distal end 3212 in anappropriate location utilizing X-Y-Z movements, a rotation about anX-axis, Y-axis, and/or Z-axis may be implemented to position the distalend 3212.

FIG. 28 depicts an exploded-perspective view of a manufacturing tool3310 comprised of six discrete vacuum distributors 3110, in accordancewith aspects of the present invention. The plate 3150 is depicted inthis exemplary aspect as having a plurality of apertures 3160 andnon-aperture portions 3170. The non-aperture portion 3170 is a portionof the plate 3150 through which apertures do not extend. For example,along a segment where two vacuum distributors 3110 converge the plate3150 may include a non-aperture portion 3170 to prevent cross feeding ofvacuum between two associated vacuum distribution cavities 3140.Further, it is contemplated that non-aperture portion 3170 may extendalong a segment in which the plate 3150 is bonded (temporarily orpermanently) to one or more portions of the vacuum distributor(s) 3110.Further yet, it is contemplated that one or more non-aperture portionsare integrated into the plate 3150 to further control the placement ofvacuum forces as dispersed along the exterior plate surface 3158.Additionally, the non-aperture portion 3170 may be implemented in anarea intended to be in contact with malleable (and othercharacteristics) portions of material that may not react well to theapplication of vacuum as transferred by one or more apertures.

FIG. 29 depicts a top-down perspective of the manufacturing tool 3310previously discussed with respect to FIG. 28, in accordance withexemplary aspects of the present invention. In particular six discretevacuum tool portions are identified as a first vacuum portion 3402, asecond vacuum portion 3404, a third vacuum portion 3406, a fourth vacuumportion 3408, a fifth vacuum portion 3410, and a fifth vacuum portion3412. In an exemplary aspect of the present invention, one or morevacuum portions may be selectively activated and deactivated. It isunderstood that this functionality may be applied to all aspectsprovided herein, but are only discussed with respect to the present FIG.29 for brevity reasons.

FIG. 30 depicts a side perspective of the manufacturing tool 3310 ofFIG. 28, in accordance with aspects of the present invention.

FIG. 31 depicts a manufacturing tool 3310 comprised of a vacuum tool3100 and an ultrasonic welder 3200, in accordance with aspects of thepresent invention. In particular, the vacuum tool 3100 of FIG. 31 is aventuri vacuum generator 3104. A venturi vacuum generator, similar to acoand{hacek over (a)} effect vacuum pump, utilizes pressurized air togenerate a vacuum force. The vacuum tool 3100 of FIG. 31 differs fromthe vacuum tool 3100 of the previously discussed figures in that thevacuum tool 3100 of FIG. 31 utilizes a single aperture as opposed to aplate having a plurality of apertures. In an exemplary aspect, theconcentration of vacuum force to a single aperture may allow for higherdegree of concentrated part manipulation. For example, small parts thatmay not require even a whole single portion of a multi-portion vacuumtool to be activated may benefit from manipulation by the singleaperture vacuum tool of FIG. 31. However, additional aspects contemplateutilizing a plate having a plurality of apertures that are not intendedfor contacting/covered-by a to-be manipulated part (e.g., resulting in aloss of suction that may traditionally be undesirable).

The single aperture vacuum tool of FIG. 31 utilizes a cup 3161 fortransferring the vacuum force from the venturi vacuum generator 3104 toa manipulated part. The cup 3161 has a bottom surface 3159 that isadapted for contacting a part. For example, a surface finish, surfacematerial, or size of the bottom surface may be suitable for contacting apart to be manipulated. The bottom surface 3159 may define a planesimilar to the plane previously discussed as being defined from theexterior plate surface 3158 of FIG. 27, for example. As such, it iscontemplated that the distal end 3212 of the ultrasonic welder 3200 maybe defined relative to the plane of the bottom surface 3159.

It is contemplated that the cup 3161 may be adjusted based on a part tobe manipulated. For example, if a part has a certain shape, porosity,density, and/or material, then a different cup 3161 may be utilized.

While two combinations of vacuum tool 3100 and ultrasonic welder 3200are depicted as forming the manufacturing tool 3310 of FIG. 31, it iscontemplated that any number of features may be implemented. Forexample, a plurality of vacuum tools 3100 may be utilized in conjunctionwith a single ultrasonic welder 3200. Similarly, it is contemplated thata plurality of ultrasonic welders 3200 may be implemented in conjunctionwith a single vacuum tool 3100. Further, it is contemplated that varioustypes of vacuum tools may be implemented in conjunction. For example, amanufacturing tool 3310 may be comprised of a single aperture vacuumtool and a multi-aperture vacuum tool (e.g., FIG. 31). Further yet, itis contemplated that one or more single aperture vacuum tools arecoupled with one or more multi-aperture vacuum tools and one or morefastening tools. As such, any number of features (e.g., tools) may becombined.

FIG. 32 depicts a top-down perspective of the manufacturing tool of FIG.31, in accordance with aspects of the present invention.

FIG. 33 depicts a side perspective of the manufacturing tool of FIG. 31,in accordance with aspects of the present invention. An offset distance3169 may be adjusted for the manufacturing tool 3310. The offsetdistance 3169 is a distance between the distal end 3212 of theultrasonic welder 3200 and the cup 3161. In an exemplary aspect, thedistance 3169 is minimized to reduce manufacturing tool 3310 travelsfrom placing a part to welding the part. However, in another exemplaryaspect, the distance 3169 is maintained sufficient distance to preventinterference in the manipulation or welding operations by the other toolportion.

FIG. 34 depicts a cut side perspective view of a manufacturing tool 3310comprised of a single aperture 3160 and an ultrasonic welder 3200, inaccordance with aspects of the present invention. The manufacturing tool3310 of FIG. 34 incorporates a moveable coupling mechanism by which theultrasonic welder 3200 is allowed to slide in a direction perpendicularto a plane defined by the bottom surface 3159. To accomplish thisexemplary moveable coupling, a biasing mechanism 3240 is implemented toregulate an amount of pressure the distal end 3212 exerts on a part,regardless of pressure being exerted in the same direction by way of thecoupling member 3300. In this example a flange 3214 slides in a channelthat is opposed by the biasing mechanism 3240. While a spring-typeportion is illustrated as the biasing mechanism 3240, it is contemplatedthat any mechanism may be implemented (e.g., gravity, counter weight,pneumatic, hydraulic, compressive, tensile, springs, and the like).

In use, it is contemplated that a force may be exerted onto a part bythe manufacturing tool 3310 that is greater than necessary for thewelding of the part by the ultrasonic welder 3200. As a result, thegreater force may be effective for maintaining a part during a weldingoperation, while the biasing mechanism 3240 may be used to apply anappropriate pressure force for a current welding operation. Further, itis contemplated that the biasing mechanism may also be used as adampening mechanism to reduce impact forces experienced by one or moreportions of the manufacturing tool 3310 when contacting objects (e.g.,parts, work surface).

In use, it is contemplated that a force may be exerted onto a part bythe manufacturing tool 3310 that is greater than necessary for thewelding of the part by the ultrasonic welder 3200. As a result, thegreater force may be effective for maintaining a part during a weldingoperation, while the biasing mechanism 3240 may be used to apply anappropriate pressure force for a current welding operation. For example,it is contemplated that the biasing mechanism 3240 may allow formovement of the distal end 3212 over a range of distances. For example,the range may include 1 mm to 10 mm, 3-6 mm, and/or about 5 mm. Further,it is contemplated that the biasing mechanism may also be used as adampening mechanism to reduce impact forces experienced by one or moreportions of the manufacturing tool 3310 when contacting objects (e.g.,parts, work surface).

Further yet, it is contemplated that instead of (or in addition to)utilizing a biasing mechanism, an amount of force exerted by anultrasonic welder 3200 (or any fastening device) may be adjusted basedon the material to be bonded. For example, a determined percentage ofcompression may be allowed for the materials to be bonded such that anoffset height of the distal end from the plate bottom surface may beadjusted to allow for the determined level of compression for particularmaterials. In practice, highly compressible material may allow for agreater distance between a distal end of the fastening tool and thebottom surface of the vacuum plate as compared to non-highlycompressible materials that would not allow for the same amount ofcompression (measured by size or force).

Further, it is contemplated that the vacuum tool 3100 is alternativelyor additionally implementing a biasing mechanism. For example, in anexemplary aspect of the present invention, the amount of pressureexerted by the vacuum tool 3100 may be desired to be less than apressure exerted by the distal end 3212 on the part. As a result, a formof biasing mechanism 3240 may be employed to controllably exert pressureon to a part by the vacuum tool 3100.

An amount of force that may be exerted by a distal end having a biasingmechanism (or not having a biasing mechanism) may range from 350 gramsto 2500 grams. For example, it is contemplated that the amount of forceexerted by the distal end on a part may increase as an amount ofdistance traveled by a biasing mechanism increases. Therefore, arelationship (e.g., based on a coefficient of the biasing mechanism) maydictate an amount of pressure applied based on a distance traveled. Inan exemplary operation, such as affixing a base material, a meshmaterial, and a skin during a welding operation, about 660 grams offorce may be exerted. However, it is contemplated that more or lessforce may be utilized.

FIG. 35 depicts a method 32600 for joining a plurality of manufacturingparts utilizing a manufacturing tool 3310 comprised of a vacuum tool3100 and an ultrasonic welder 3200, in accordance with aspects of thepresent invention. A block 32602 depicts a step of positioning themanufacturing tool 3310 such that the vacuum tool 3100 is proximate afirst part. As used herein, the term proximate may refer to a physicalrelationship that includes being at, on, and near. For example, themanufacturing tool may be proximate a location when it is within alength or width of the manufacturing tool from the location. Further, itis contemplated that the manufacturing tool is proximate a location whenthe manufacturing tool is at a location defined to be within toleranceof the part to be manipulated. The positioning of the manufacturing tool3310 may be accomplished by a positional member, previously discussed.In turn, the positional member may be in communication with apart-recognition system that directs the placement of the manufacturingtool based on image analysis of the first part.

A block 32604 depicts a step of generating a vacuum force transferredthrough a bottom surface of the vacuum tool 3100. For example, one ormore of the vacuum generators 3102 may be activated (e.g., as a whole,selectively) to generate a vacuum force that results in a suction effectattracting a part to the exterior plate surface 3158 of FIG. 28 (or thebottom surface 3159 of FIG. 31). As previously discussed, it iscontemplated that one or more vacuum portions may be selectivelyactivated (or deactivated) depending on a desired amount of vacuum forceand a desired location of vacuum force.

A block 32606 depicts a step of temporarily maintaining the first partin contact with at least a portion of the vacuum tool 3100. Therefore,once a vacuum is applied to a part and the part is attracted to thevacuum tool 3100, the part is maintained in contact with the vacuum tool3100 so that if the vacuum tool moves (or an underlying supportingsurface of the part moves) the part will stay with the vacuum tool. Theterm temporarily is utilized in this sense so as not to imply apermanent or otherwise significant bond that requires significant effortto separate the part from the vacuum tool. Instead, the part is“temporarily” maintained for the duration that a sufficient vacuum forceis applied.

A block 32608 depicts a step of transferring the first part to a secondpart. The first part may be transferred though a movement of themanufacturing tool 3310. The movement of the manufacturing tool may beaccomplished by a positional member, previously discussed. In turn, thepositional member may be in communication with a part-recognition systemthat directs the transfer of the first part to the second part based on,for example, image analysis of the second part. Further, it iscontemplated that the transferring of the first part may be accomplishedthrough the movement of the second part to the first part (e.g.,underlying conveyor system brings the second part towards the firstpart).

A block 32610 depicts a step of releasing the first part from the vacuumtool 3100. For example, it is contemplated that stopping the generationof vacuum pressure by one or more vacuum generators 3102 is sufficientto effectuate the release of the first part. Further, it is contemplatedthat a burst of air that is insufficient to generate a vacuum (e.g.,insufficient to take advantage of a coand{hacek over (a)} effect) in thevacuum generator 3102, but sufficient to cause the release the part maybe implemented.

Further, it is contemplated that the releasing of the first part furthercomprises activating another mechanism that opposes the vacuum pressureof the vacuum tool 3100. For example, a work surface (e.g., conveyor,table top) opposite of the vacuum tool 3100 may generate a vacuumpressure that counters the vacuum of the vacuum tool. This may allow forprecise placement and maintaining of the part as the vacuum tool againtransitions to a new position. The countering vacuum pressure may begenerated with a mechanical vacuum (e.g., blower) as cycling off and onmay not be needed at the same rate as the vacuum tool 3100.

In an exemplary aspect of the present invention, it is contemplated thata work surface vacuum and a vacuum tool vacuum may have the followingon/off relationship for exemplary processes, as depicted in thefollowing tables. While exemplary process are indicated, it iscontemplated that additional processes may be substituted or re-arrangedwithin the process. Further, a manufacturing surface, as used herein,reference to a moveable article that may form a base for initiallysecuring, maintaining, aligning, or otherwise assisting in themanufacturing of a product resulting from the manipulated part(s).

Simplified Operations Table Work Surface Vacuum Tool Operation VacuumVacuum Initial State Off Off Manufacturing surface arrives On Off Robotstarts to move vacuum On Off tool for part pickup Robot reaches X %distance On On from part Robot begins moving vacuum On On tool with partto place the part Place the part On Off Affixing of part (e.g., welding)On Off End state On Off

Additional Operations Table Work Surface Vacuum Tool Operation VacuumVacuum Initial State Off Off Manufacturing surface arrives On Off Robotstarts to move vacuum On Off tool for part pickup Robot reaches X %distance On On from part Robot begins moving vacuum On On tool with partto place the part Robot reaches Y % distance Off On from themanufacturing surface Wait Z seconds Off On Place the part Off Off Robotbegins moving Off Off Robot positions welder On Off Affixing of part(e.g., welding) On Off End state On Off

Consequently, it is contemplated that any combination of work surfacevacuum and vacuum tool vacuum may be utilized to accomplish aspects ofthe present invention. In an exemplary aspect the work surface vacuum ismaintained on while a manufacturing surface is present. As a result, thework surface vacuum may utilize a mechanical vacuum generator that maybe more efficient, but requires a start up or wind down time than acoanda or a venturi vacuum generator. Further, a mechanical vacuumgenerator may be able to generate a greater amount of vacuum force overa larger area than the coanda or venturi vacuum generators typicallygenerate.

A block 32612 depicts a step of positioning the manufacturing tool 3310such that the distal end 3212 of the ultrasonic welder 3200 is proximatethe first part. The positioning of the ultrasonic welder may be inresponse to instructions received from a part-recognition system asoutlined above. In this example, it is contemplated that the first partand the second part are intended to be joined utilizing the ultrasonicwelder 3200. Consequently, the ultrasonic welder is positioned in amanner to apply an ultrasonic induced bond between the first part andthe second part. The ultrasonic induced bond may be temporary (i.e., fortacking purposes) or permanent.

A block 32614 depicts a step of applying an ultrasonic energy throughthe horn 3210. The application of ultrasonic energy bonds the first andthe second part with an ultrasonic weld.

While various steps of the method 32600 have been identified, it iscontemplated that additional or fewer steps may be implemented. Further,it is contemplated that the steps of method 32600 may be performed inany order and is not limited to the order presented.

Additional arrangements, features, combinations, subcombination, steps,and the like are contemplated within the provided disclosure. As such,additional embodiments are inherently disclosed by the provideddiscussion.

What is claimed is:
 1. A method for positioning and assembling a shoepart in an automated manner during a shoe-manufacturing process, themethod comprising: receiving an image depicting a two-dimensionalrepresentation of an attachment shoe part which is to be attached to abase shoe part; determining one or more pixel coordinates of the image;converting, by a computer processor, the one or more pixel coordinatesof the image to a geometric coordinate of a geometric coordinate systemwhich maps a three-dimensional space within which the attachment shoepart is positioned and a pick-up tool operates; determining anothergeometric coordinate of the geometric coordinate system by analyzing adifferent image depicting a two-dimensional representation of the baseshoe part to which the attachment shoe part will be attached; andtransferring, by the pick-up tool, the attachment shoe part to the othergeometric coordinate, thereby moving the attachment shoe part to alocation in the three-dimensional space at which the attachment shoepart is to be attached to the base shoe part.
 2. The method of claim 1,wherein the two-dimensional representation of the attachment shoe partis comprised of a two-dimensional shape having a perimeter and whereinthe one or more pixel coordinates of the image are associated with theperimeter.
 3. The method of claim 1, further comprising determining theidentity of the image by substantially matching the image to a referenceimage.
 4. The method of claim 1, wherein transferring the attachmentshoe part to the other geometric coordinate comprises utilizing avacuum-powered part holder of the pick-up tool to transfer theattachment shoe part.
 5. The method of claim 1, further comprisingattaching the attachment shoe part to the base shoe part.
 6. A method ofpositioning and joining a plurality of shoe parts utilizing automatedidentification of the shoe parts and a multi-functional manufacturingtool, the method comprising: receiving an image depicting atwo-dimensional representation of an attachment shoe part which is to beattached to a base shoe part; determining a geometric coordinate of ageometric coordinate system by analyzing the image, wherein thegeometric coordinate system maps a three-dimensional space within whichthe attachment shoe part is positioned and the multi-functionalmanufacturing tool operates; determining another geometric coordinate ofthe geometric coordinate system by analyzing a different image depictinga two-dimensional representation of the base shoe part to which theattachment shoe part will be attached; transferring, by the amulti-functional manufacturing tool, the attachment shoe part to theother geometric coordinate, thereby moving the attachment shoe part to alocation in the three-dimensional space at which the attachment shoepart is to be attached to the base shoe part; and attaching, by themulti-functional manufacturing tool, the attachment shoe part to thebase shoe part.
 7. The method of claim 6, wherein determining thegeometric coordinate of the geometric coordinate system by analyzing theimage comprises determining pixel coordinates of the image andconverting the pixel coordinates of the image to the geometriccoordinate of the geometric coordinate system.
 8. The method of claim 7,wherein transferring the attachment shoe part to the other geometriccoordinate comprises utilizing a vacuum-powered part holder of themulti-functional manufacturing tool to transfer the attachment shoepart.
 9. The method of claim 6, wherein attaching the attachment shoepart to the base shoe part comprises utilizing an ultrasonic weldinghorn of the multi-functional manufacturing tool to attach the attachmentshoe part to the base shoe part.
 10. A system that positions andattaches a shoe part in an automated manner during a shoe-manufacturingprocess, the system comprising: an image recorder that records an imagedepicting a two-dimensional representation of an attachment shoe part,which is to be attached to a base shoe part; and computer storage mediahaving stored thereon computer-executable instructions that, whenexecuted, cause a computing device to: (1) determine pixel coordinatesof the image, (2) convert the pixel coordinates of the image to ageometric coordinate in a geometric coordinate system, which maps athree-dimensional space within which the attachment shoe part ispositioned and a manufacturing tool operates, (3) determine anothergeometric coordinate in the geometric coordinate system by analyzing adifferent image of the base shoe part, and (4) instruct a manufacturingtool to transfer the attachment shoe part to the other geometriccoordinate, thereby moving the attachment shoe part to a location in thethree-dimensional space at which the attachment shoe part is to beattached to the base shoe part.
 11. The system of claim 10 furthercomprising another image recorder, wherein the different image of thebase shoe part is recorded by the other image recorder.
 12. The systemof claim 10 further comprising a light-emitting device that provides abacklight to the attachment shoe part when the image is recorded. 13.The system of claim 10, wherein the manufacturing tool comprises atleast a vacuum-powered part holder having a bottom surface adapted forcontacting the attachment shoe part.
 14. The system of claim 13, whereinthe vacuum-powered part holder is comprised of a vacuum plate having aplurality of apertures extending through an interior plate surface andthe bottom surface.
 15. The system of claim 13, wherein thevacuum-powered part holder is comprised of a single aperture extendingthrough the bottom surface.
 16. The system of claim 13 wherein themanufacturing tool further comprises at least an ultrasonic-welding horncoupled to the vacuum-powered part holder.
 17. The system of claim 16,wherein the ultrasonic-welding horn comprises at least a distal endadapted for contacting the attachment part such that the distal endextends at least to a plane defined by the vacuum-powered part holderbottom surface.
 18. The system of claim 17, wherein only one of thevacuum-powered part holder or the ultrasonic-welding horn are useablefor a respective intended purpose at one time.
 19. The system of claim17, wherein both of the vacuum-powered part holder and theultrasonic-welding horn are useable for their respective intendedpurpose at one time.